Model Variant:
Enduro/Off-Road
Year Range Covered:
1999, 2000, 2001, 2002, 2003
Engine Code Identifier:
Likely LC2 200 variant, specific code not provided but consistent with KTM nomenclature for this era.
Motorcycle Segment:
Lightweight, aggressive off-road enduro motorcycle.
Target Audience:
Enthusiasts participating in off-road riding, trail riding, motocross (depending on specific tuning), and amateur competition.
Competitors Era:
Honda CR250R, Yamaha YZ250, Suzuki RM250, Kawasaki KX250 (2-stroke variants, though the KTM 200 may have had a 2-stroke or a unique 4-stroke configuration depending on exact model year and market).
Ktm Brand Philosophy:
'Ready to Race' ethos, emphasizing performance, robust construction, and off-road capability.
Model Strengths:
Agile handling, strong power-to-weight ratio, durable components (especially suspension for the era).
Coverage Scope:
Comprehensive service, repair, and maintenance for KTM 200 EXC models from 1999-2003.
Page Count Estimate:
Estimated 300-500 pages (typical for full service manuals of this era).
Manual Type:
Full Service and Repair Manual
Language:
English (presumed, standard for most aftermarket manuals).
Format:
Digital (PDF) - Highly likely given the product description context, though physical copies also existed.
Engine Systems:
Engine disassembly, assembly, inspection, carburetor tuning, ignition system, cooling system (if applicable), lubrication, exhaust system.
Transmission Drivetrain:
Clutch operation, gearbox disassembly and assembly, chain and sprockets maintenance, final drive.
Chassis Suspension:
Front fork (WP Suspension typically) overhaul and service, rear shock absorber (WP Suspension) service and adjustments, swingarm and linkage maintenance, steering head bearing service.
Brakes:
Hydraulic brake system inspection, fluid replacement, caliper and master cylinder service, pad replacement, disc inspection.
Electrical System:
Wiring diagrams, lighting system, battery maintenance, ignition coil testing, stator and rotor inspection, starter motor (if electric start), switches and controls.
Fuel System:
Fuel tank inspection, fuel lines, fuel filter replacement, carburetor cleaning and jetting.
Bodywork Frame:
Fairings, plastics, seat removal, frame inspection, footpegs, handlebars.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, chain lubrication and adjustment, air filter cleaning/replacement, tire pressure checks, brake pad wear checks.
Troubleshooting:
Diagnostic charts for common performance issues, starting problems, electrical faults, and mechanical noises.
Rebuild Procedures:
Detailed step-by-step instructions for engine top-end rebuild (piston, rings, cylinder), clutch overhaul, gearbox repairs, suspension fork rebuilds.
Technical Adjustments:
Carburetor idle speed and mixture adjustments, ignition timing checks (where applicable), suspension sag and damping adjustments.
Depth Of Coverage:
Comprehensive. Covers everything from basic owner maintenance to complete engine rebuilds and complex electrical diagnostics. Essential for DIY mechanics and professional workshops.
File Type:
PDF (Portable Document Format) - Assumed for digital product.
Searchability:
Likely text-searchable if a professionally produced PDF.
Print Readability:
Designed for clear printing of text, diagrams, and illustrations.
Binding Type Physical:
N/A (Digital format) - If a physical copy existed, it would likely be a spiral-bound or saddle-stitched manual for lay-flat use.
Paper Type Physical:
N/A (Digital format) - If a physical copy existed, typically durable, possibly glossy paper for diagrams.
Engine Type:
Likely a 193cc (approximate) single-cylinder, two-stroke engine. Specific engine architecture would be detailed in the manual.
Bore X Stroke:
Specific values not provided in product info, but typical for this displacement range (e.g., ~64mm x 58mm).
Cooling System:
Liquid-cooled
Ignition System:
Digital CDI (Capacitor Discharge Ignition)
Horsepower Estimate:
Estimated 35-45 HP, depending on tuning and specific model variant.
Torque Estimate:
Estimated 25-30 lb-ft, depending on tuning.
Carburetor Type:
Likely a Keihin PWK or similar performance-oriented carburetor (e.g., 38mm).
Fuel Type:
Unleaded gasoline (95 RON or higher recommended), mixed with 2-stroke oil for lubrication.
Fuel Mixture Ratio:
Typically 40:1 or 50:1, specified by KTM in the original owner's manual. Manual will detail this.
Wheelbase Estimate:
Approximately 1450-1480 mm (57-58 inches).
Seat Height Estimate:
Approximately 930-950 mm (36.6-37.4 inches).
Dry Weight Estimate:
Approximately 98-105 kg (216-231 lbs).
Fuel Tank Capacity Estimate:
Approximately 8-10 liters (2.1-2.6 gallons).
Safety Standards:
Designed for off-road use; no road legal safety ratings like NCAP apply. Focus on rider protection via motorcycle design and rider skill.
Braking System:
Hydraulic disc brakes front and rear. Typically Brembo calipers were used by KTM in this era.
Suspension Performance:
WP USD (Upside Down) front forks and WP PDS (Progressive Damping System) rear shock, providing excellent ground clearance and bump absorption.
Frame Construction:
Chromoly steel trellis frame, offering high strength and rigidity.
Engine Oil Change:
Every 10-15 hours of riding or annually. Manual will provide exact interval.
Air Filter Cleaning:
Every 5-10 hours of riding, or more frequently in dusty conditions. Manual will specify.
Spark Plug Service:
Every 20-30 hours of riding. Manual will specify type and gap.
Top End Rebuild:
Every 40-60 hours of riding for optimal performance. Manual will detail piston and ring wear limits.
Engine Oil Type:
Specific 2-stroke semi-synthetic or fully synthetic oil. Manual will list KTM-approved brands and viscosity grades (e.g., Motorex).
Transmission Oil Type:
Specific transmission oil or high-quality engine oil meeting JASO MA specifications. Manual will specify type and capacity (e.g., Motorex Gear Oil 75W/80).
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Coolant Type:
Ethylene glycol-based coolant with anti-corrosion additives (e.g., Motorex Coolant M3.0).
Carburetor Jetting:
Can require fine-tuning based on altitude, temperature, and modifications. Manual will cover jetting charts.
Clutch Wear:
Clutch plates may wear over time, especially with aggressive riding. Manual will cover inspection and replacement.
Suspension Seals:
Fork and shock seals can leak, requiring periodic service. Manual will detail seal replacement procedures.
Brand Awards:
KTM has a long history of awards in motocross and enduro racing across various categories and model lines.
Motorcycle Reviews:
The KTM 200 EXC from this era was generally well-regarded for its performance, handling, and KTM's off-road pedigree. Specific reviews will highlight its capabilities.
Manufacturing Quality:
Adherence to European manufacturing standards for off-road motorcycles.
